Vacuum cleaner multi-directional brushroll/agitator

ABSTRACT

A vacuum cleaner brushroll/agitator assembly that sweeps carpets/rugs from two opposing directions during vacuum operation. This dual sweeping motion is accomplished by assembling smaller brushroll Sections onto a Center Axle to equal the length and size of the traditional, one-piece brushroll. Each Section rotates in the opposite direction of the adjacent Sections. The new art solves the problem of carpet fibers being constantly swept from only one (the same) side of the fibers during each repetitive-pattern vacuuming episode.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to the earlier-filed Provisional Application No. US 61/495,937—filed on Jun. 10, 2011.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

(Not applicable)

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX

(Not applicable)

BACKGROUND OF THE INVENTION

Vacuum cleaners typically clean carpets and rugs by utilizing a rotary brushroll or agitator that rapidly sweeps the carpet fibers. The vacuum cleaner then utilizes its suction power to remove loose particles and dirt. Prior art consists of a solid brushroll that limits the sweeping of the carpet fibers to only one direction (the single-direction of rotation of the brushroll).

Carpets are typically repeatedly vacuumed in the same pattern (since the vacuum cleaner and its operator typically gain access to a room from the same point of entrance each time). The result is that carpet fibers are constantly being swept from only one direction; i.e., the carpet fibers are being contacted by the vacuum cleaner agitator from only one side of the fiber. Carpet manufacturers recommend that an operator of a vacuum cleaner periodically change the direction from which he or she vacuums so that the carpet fibers are swept from an alternative direction.

BRIEF SUMMARY OF THE INVENTION

A vacuum cleaner brushroll/agitator ASSEMBLY that sweeps carpets/rugs from two opposing directions.

The traditional solid brushroll is replaced by a brushroll/agitator assembly of the same length and diameter however, the brushroll is now comprised of (typically) six (6) smaller brushroll Sections mounted onto a Center Axle. The Center Axle is squared and extends the width of the inside of the vacuum cleaner brushroll housing. Each brushroll Section extends slightly into or over the adjacent Section such that the internal workings of the completed brushroll/agitator assembly are invisible. Each brushroll Section rotates on Bushings or Sleeves in a direction that is opposite of the direction of rotation of the adjacent brushroll Section. The alternating direction of rotation of each Section is accomplished by securing a teethed disc or ring gear (Internal Endcap) into the ends of each brushroll Section. Mounted onto the Center Axle between each Section (invisible once the assembly is completed) is a “Directional Disc”. The Directional Disc has bevel gears mounted in cutouts on the Disc (cutouts in the north, south, east, and west positions on the Disc).

The bevel gears on the Directional Disc engage with the teeth on the Internal Endcaps of each brushroll Section. The traditional belt from the brushroll motor rotates the first Section of the completed assembly, which then engages the first Directional Disc, which then rotates the second Section in the opposite direction of the first, which then engages the second Directional Disc, which then rotates the third Section in the opposite direction of the second, which then engages the next Directional Disc, and so on.

Carpet cleaning is much improved and carpet life is extended as the carpet fibers are no longer relegated to being manipulated or swept in a single direction by the brushroll/agitator.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1—Fully assembled Sectional brushroll/agitator (shown without bristles).

FIG. 2A—Brushroll Section facade view (shown without bristles).

-   -   2B—Brushroll Section cross-section view.

FIG. 3—Internal Endcap (ring gear)—inserted into brushroll/agitator Section.

FIG. 4A—External Endcap (belt-driven) facade view—secured to outside end of final Section of brushroll/agitator assembly.

-   -   4B—External Endcap (belt-driven) end view.

FIG. 5A—External Endcap (passive) facade view—secured to outside end of initial Section of brushroll.

-   -   5B—External Endcap (passive) end view.

FIG. 6A—Directional Disc facade view—placed between each brushroll Section. Transfers/converts rotation of one section into opposite rotation of the next Section.

FIG. 6B—Directional Disc edge view

FIG. 7A—Bushing facade view (alternative to Sleeve)—inserted into center opening of internal and external Endcaps to allow mounting of brushroll/agitator Section onto (squared) Center Axle.

-   -   7B—Bushing edge view.

FIG. 8A—Sleeve facade view (alternative to Bushing)—inserted through center opening of Internal and External Endcaps—extending beyond the length of each brushroll/agitator Section—to allow mounting of each Section onto the (squared) Center Axle.

-   -   8B—Sleeve end view.

FIG. 9A—Center Axle facade view—runs the length of the inside of the brushroll/agitator housing; each brushroll Section is mounted onto the Center Axle via Endcaps and Bushings or Sleeves.

-   -   9B—Center Axle cross-section view.

FIG. 10—Lockring facade view (alternative to Axle Cap)—mounted onto each end of Center Axle; abuts outside of Passive and Belt-Driven External Endcaps to restrict lateral movement of the final assembly along Center Axle.

FIG. 11A—Axle Cap facade view (alternative to Lockring)—mounted onto each end of Center Axle; abuts outside of Passive and Belt-Driven External Endcaps to restrict lateral movement of final assembly along Center Axle.

-   -   11B—Axle Cap top view.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The Sectional, Multi-Directional Brushroll/Agitator consists of several smaller brushroll Sections that are assembled onto a squared Center Axle. When fully assembled, the new art is of the same length and diameter as the prior art single/solid brushroll.

The fully-assembled Sectional Brushroll/Agitator includes internal mechanisms that will cause each Section to rotate on the Center Axle in the opposite direction of the adjacent brushroll Sections—thus allowing carpets and rugs to be swept from two opposing directions.

The new art includes:

Squared Center Axle—Mounted into recesses of the inside walls of the vacuum cleaner brushroll housing. Center Axle is preferably hollow for rigidity and light weight.

Brushroll Sections—Hollow, cylindrical “mini” brushrolls (typically six for a standard household vacuum cleaner) that are assembled onto the Center Axle. The finished product is of the same size as the prior-art solid/single brushroll that is being replaced. Each Section has a male end and a female end that allows each Section to fit slightly into or around the adjacent Sections. An Internal Endcap is installed into each end of each Section (save the outward-facing ends of the first and last Sections). Endcaps can be secured by crimping Sections around perimeter of Endcaps, by screwing Sections into perimeter of Endcaps, or via adhesion. An External Endcap is installed on the outward-facing ends of the first and last Sections.

Internal/External Endcaps—Mounted into the ends of each Section (Internal Endcap) or around the perimeter of each Section (External Endcap). Internal Endcaps are essentially ring gears that will couple with the bevel gears on the Directional Disc.

Bushings OR Sleeves—Mounted onto the Center Axle and fits into the center opening of each Internal and External Endcap. Bushings or Sleeves allow the Internal and External Endcaps—thus allow each Section—to rotate on the (squared) Center Axle.

Directional Disc—A thin disc with bevel-shaped openings in the north, south, east, and west positions on the Disc. Small bevel gears are mounted in the openings by inserting pins through the edge of the Directional Disc, through the center of each bevel gear and into the body of the Disc. Each gear rotates on its own pin. The Directional Disc has a squared center opening. The Disc is mounted onto the squared Center Axle between each brushroll Section. The bevel gears of each Disc will couple with the Internal Endcaps of each Section. Rotation of one Section causes the Internal Endcap of that Section to rotate the bevel gears on the Directional Disc. Rotation of the bevel gears will cause the next Section to rotation in the opposite direction.

Lockring OR Axle Cap—Mounted onto the Center Axle outside of the first and last installed brushroll Sections. The Lockrings or Axle Caps will abut the outward-facing facades of the Passive & Belt-Driven External Endcaps. Once installed, they will prevent lateral movement of the fully-assembled brushroll/agitator along the Center Axle.

Assemblage

The new art Sectional Brushroll/Agitator consists of six (6) smaller brushroll Sections mounted onto a squared Center Axle. When fully assembled, the completed product is of the same length and diameter—and assumes the same space in the vacuum cleaner brushroll head or nozzle—as a traditional one-piece brush roller.

-   -   * * All instructions refer to a six (6) section         brushroll/agitator (no. of sections can be increased or         decreased) **

Directional Disc—Insert 4 bevel gears into the four cutouts of each disc and secure them in the cutouts by inserting mounting pins through the edge of the Disc, through the center of each gear, and into the body of the Disc.

Brushroll Section—For the four inner Sections of the assembly, secure a large Internal Endcap into the female end of each Section and a small Internal Endcap into the male end of each Section.

-   -   For the two Sections on the ends (Sections 1 and 6):         -   Section 1—Secure a Passive External Endcap to the female end             of the Section; secure a small Internal Endcap into the male             end of the Section (Internal Endcap is recessed into the             Section).         -   Section 6—Secure a large Internal Endcap into the female end             of the Section (Internal Endcap is recessed into the             Section); secure a Belt-Driven External Endcap to the male             end of the Section.

Brushroll/Agitator—From the left end of the Center Axle slide a Bushing onto the Axle then place a metal Lockring or Axle Cap on the Axle in contact with the left side of the Bushing. Leave just enough of the Center Axle protruding to the left of the Lockring to mount the Axle into the recess of the brushroll/agitator housing of the vacuum cleaner (if Axle Cap is used, top of Axle Cap will mount into recess of brushroll/agitator housing).

-   -   The Bushings fit snugly enough onto the Center Axle so as to not         allow lateral movement of the Bushings during normal operation         of the brushroll/agitator. Alternatively, Sleeves can be         installed instead of Bushings. The Sleeves would extend through         the center of each brushroll Section from Directional Disc to         Directional Disc.     -   Final assembly of the Sectional Brushroll/Agitator will cause         the Directional Discs to prevent lateral movement of the         Sleeves.     -   The Lockring or Axle Cap is of a sufficient outside diameter so         as to not allow the adjacent Section to move laterally past the         Lockring or Axle Cap (i.e., the outside diameter of the Lockring         or Axle Cap is slightly larger than the center openings of the         Passive and Belt-Driven Endcaps).     -   Place Brushroll Section 1 (with Passive External Endcap) onto         the Center Axle from the right end of the Axle—External Endcap         first. Slide it all the way to the left end of the Axle, fitting         the opening in the External Endcap of the Section onto the         previously installed Bushing (or Sleeve). If a Bushing (instead         of a Sleeve) was installed in the initial assembly step, now         install a second Bushing onto the right end of the Center Axle.         Slide the Bushing all the way down to Brushroll Section 1 and         into the opening of the Internal Endcap of the Section.     -   Section 1 should now rotate freely in either direction on the         Center Axle.     -   Slide a Directional Disc onto the Center Axle and in contact         with the Internal Endcap of the first brushroll Section. The         bevel gears of the Directional Disc should mesh with the teeth         of the Internal Endcap of brushroll Section 1.     -   Slide another Bushing onto the Center Axle to the right of the         Directional Disc; mount brushroll Section 2 (female end) onto         this Bushing. Slide a Bushing onto the Axle and into the opening         of the Internal Endcap of the male end of Section 2.     -   Brushroll Section 2 should now rotate freely in either direction         on the Center Axle—causing Brushroll Section 1 to rotate in the         opposite direction.     -   Slide another Directional Disc onto the Center Axle and in         contact with Brushroll Section 2. Continue to install Bushings,         brushroll Sections, and Directional Discs in the above sequences         through brushroll Section 6.     -   Upon installing Brushroll Section 6, the Belt-Driven External         Endcap should face the right end of the Center Axle. A Lockring         or Axle Cap should then be installed on the Axle to the right of         Section 6 to prevent lateral movement to the right of all         brushroll Sections (the first installed Lockring or Axle Cap         will prevent lateral movement to the left).     -   Installation of the Lockring or Axle Cap should leave just         enough of the Center Axle protruding to the right of the final         Section to allow mounting of the Axle into the recess of the         roller brush housing of the vacuum cleaner (if Axle Cap is used,         the “top” of the Axle Cap would be mounted into the recess of         the inside wall of the vacuum cleaner brushroll housing).

The brushroll/agitator assembly is now complete.

With the vacuum cleaner motor belt attached to the Belt-Driven External Endcap of brushroll Section 6, each brushroll Section will now rotate in alternating directions when the vacuum cleaner is operated. 

1. A vacuum cleaner brushroll/agitator whereby the traditional one-piece brushroll/agitator is replaced by the assemblage of several smaller brushroll “Sections” mounted onto a squared Center Axle (six sections would be ideal on a typical household vacuum cleaner, Number of sections can be decreased or increased to adapt to vacuum cleaner type and size), Also mounted onto the Center Axle—between each Section—is a Directional Disc which transfers the direction of rotation of one Section into opposite directional rotation of the next Section, This new art allows carpet fibers to be swept from two opposing directions during a routine vacuuming episode.
 2. Each Section of the brushroll assemblage of claim 1 is made of nylon, plastic polymer, metal, or other durable material.
 3. Each Section of the brushroll assemblage of claim 1 is hollow for light weight and to allow for the insertion of Internal Endcaps (ring gears) at each end of the Section.
 4. Each Section of the brushroll assemblage of claim 1 has one male end and one female end, This allows each section to fit slightly into or around the adjoining section such that the internal workings of the final assemblage are invisible.
 5. Each Section of claim 1 is completed by installing an Internal Endcap into each end (save the outward-facing ends of the first and last Sections).
 6. A Passive External Endcap is installed on the outward-facing end of the first brushroll Section of the final assemblage of claim 1; A Belt-Driven External Endcap is installed on the outward-facing end of the final (last) Section of claim
 1. 7. The outside diameter of each Internal Endcap of claim 5 is approximately the same as the inside diameter of either the female end of each brushroll Section or the (smaller) male end of each Section.
 8. The face of each Internal Endcap of claim 5 is a ring gear, The teeth of the ring gear is designed to mesh with the teeth of the bevel gears that are installed on the Directional Disc of claim
 1. 9. Each Internal Endcap of claim 5 is installed in each brushroll Section in a recessed position within the Section, This will allow—upon final assembly of the Sectional Brushroll/Agitator—each Internal Endcap to mesh with a Directional Disc that will be installed between each Section while still allowing each Section to fit slightly into or around each adjacent Section.
 10. The Center Axle of the final assembly of claim 1 is squared, hollow (for rigidity and light weight) and is of a sufficient length to extend beyond the combined total length of the assembled brushroll Sections.
 11. The length of the Center Axle of the final assembly of claim 1 is sufficient to extend from one internal side of the vacuum cleaner nozzle housing to the opposing internal side of the nozzle housing.
 12. The Center Axle of claim 1 mounts into recesses of the internal sides of the vacuum cleaner nozzle housing.
 13. The Directional Disc of claim 1 is a thin nylon, plastic, or metal disc with bevel-shaped cut-outs in the north, south, east, and west positions.
 14. The Directional Disc of claim 1 has a squared center opening, The opening is approximately the same size as the outside dimensions of the Center Axle, allowing the Directional Disc to be mounted onto the Center Axle between each brushroll Section, The squared opening will prevent the Directional Disc from rotating during brushroll operation.
 15. The outside diameter of the Directional Disc of claim 1 does not exceed the outside diameter of the male end of each brushroll Section, This will allow the Directional Disc—along with the male end of each Section—to fit into (and be hidden by) the female end of the next Section.
 16. The Directional Disc of claim 1 has bevel gears installed in the bevel cutouts of each Directional Disc, The gears are installed by inserting pins through the edge of the Disc, with each pin entering the bevel cutout, passing through the center of each bevel gear, and into the body of the Directional Disc, The pins are secured either by tension (“tight fit” through the opening in the edge of the Disc) or via adhesion.
 17. Round Bushings are a part of the installation of each brushroll Section onto the Center Axle of claim 1—fitting into the center openings of each Internal Endcap of claim 5 and each External Endcap of claim 6, The outside diameter of each bushing is slightly less than the diameter of the center opening of each Internal and External Endcap—thus allowing each Endcap (ergo, each Section) to rotate on the squared Center Axle.
 18. Each Bushing of claim 17 has a thickness that is equal to—or slightly greater than—the thickness of the center opening of each Internal and External Endcap.
 19. Each Bushing of claim 17 has a squared center opening to allow installation of the Bushing onto the squared Center Axle, The Bushing fits snugly onto the Center Axle to resist lateral movement of the Bushing along the Center Axle during normal operation of the brushroll/agitator
 20. As an alternative to Bushings, Sleeves can be used as part of the installation of each brushroll Section onto the Center Axle of claim 1, The Sleeves would be made of the same material as the Bushings.
 21. The Sleeve of claim 20, wherein the center opening would be square, The dimensions of the center opening would be approximately the same as the outside dimensions of the squared Center Axle to allow the Sleeve to be inserted onto the Center Axle.
 22. The Sleeve of claim 20 would be inserted into each assembled brushroll/agitator Section.
 23. The Sleeve of claim 20 would have a length greater than the length of each assembled Section, sufficient to contact the face of one Directional Disc, pass through the center of each assembled Section, then contact the face of the next Directional Disc—thus preventing lateral movement of the Sleeve along the Center Axle.
 24. The outside diameter of each Sleeve of claim 20 is the same as that of each Bushing of claim
 17. 25. Two Lock Rings or Axle Caps are used to bind the assembled parts of claim 1 onto the Center Axle.
 26. If Lock Rings are used as part of claim 25, a sufficient length of the Center Axle of claim 10 extends beyond each Lock Ring such that each end of the Center Axle can be mounted into recesses of the inside walls of the vacuum cleaner brushroll housing.
 27. If Axle Caps are used as part of claim 25, each end of the Center Axle would extend into each Axle Cap and the “tops” of the Axle Caps would be mounted into recesses of the inside walls of the vacuum cleaner brushroll housing. 